Technical knit archtectures for comfort seating

ABSTRACT

A vehicle seat includes a first knitted fabric layer defining an outer surface and a second knitted fabric layer defining an inner surface. The inner surface is opposite the outer surface. The vehicle seat further includes a knitted spacer fabric interconnecting the first knitted fabric layer and the second knitted fabric layer. The knitted spacer fabric resiliently biases the first knitted fabric layer and the second knitted fabric layer away from one another. The knitted spacer fabric is configured to buckle when a seated occupant exerts an occupant load on the vehicle seat. The first knitted fabric layer is more elastic than the second knitted fabric layer to conform to the seated occupant when the seated occupant exerts the occupant load on the vehicle seat.

INTRODUCTION

The present disclosure relates to technical knit architectures forcomfort seating.

A seat assembly, such as a seat assembly for a vehicle, includes agenerally upright seat back and a generally horizontal lower seat base.Each of the seat back and the seat base typically includes a frame, asuspension, a cushion, and a trim material. The trim material is used tocover the cushion, suspension and frame, and to provide an exteriorsurface for contact with an occupant of the seat assembly. The frameprovides the support structure to attach the seat back and the lowerseat base to each other and/or to the vehicle. The cushion is typicallymade from an expandable foam material and is molded to a predeterminedshape as required by the shape of the seat back and the lower seat base.The configuration of the trim material, the cushion and the suspensioncollectively determine the contact area of an occupant seated in theseat assembly, and the pressure distribution of the contact pressureexperienced by the seated occupant. The comfort of the seated occupantis affected by the area and pattern of the occupant's contact with thelower seat base and the seat back surfaces, and by the maximum contactpressure and the pressure distribution of the contact pressureexperienced by the seated occupant.

SUMMARY

The present disclosure relates to a vehicle seat with technical knitarchitectures for comfort seating. For this new type of seating, theknitted structures disclosed herein would be nominally replacing thestandard cushion and suspension. In addition to serving a trim forseating, the presently disclosed 3D knitted structure may also besuspended from the frame and serve as a cushion, suspension and trim. Insome embodiments, the vehicle seat includes a first knitted fabric layerdefining an outer surface and a second knitted fabric layer defining aninner surface. The inner surface is opposite the outer surface. Thevehicle seat further includes an interconnection, such as a knittedspacer fabric, that couples the first knitted fabric layer to the secondknitted fabric layer. The knitted spacer fabric resiliently biases thefirst knitted fabric layer and the second knitted fabric layer away fromone another. The knitted spacer fabric is configured to buckle when aseated occupant exerts an occupant load on the vehicle seat or frame.The first knitted fabric layer is more elastic than the second knittedfabric layer to conform to the seated occupant when the seated occupantexerts the occupant load on the vehicle seat. The tension in the secondknitted fabric layer is higher than the tension in the first knittedfabric layer. The interconnection may include the knitted spacer fabric,and the knitted spacer fabric may include a plurality of pile yarnsinterconnecting the first knitted fabric layer and the second knittedfabric layer. The plurality of pile yarns may resiliently bias the firstknitted fabric layer and the second knitted fabric layer away from eachother. The first knitted fabric layer may be more compliant than thesecond knitted fabric layer to allow the first knitted fabric layer toconform to the seated occupant when the seated occupant exerts theoccupant load on the vehicle seat or frame.

In some embodiments, the knitted spacer fabric includes a first supportarea and a second support area spaced apart from each other along ahorizontal direction, the first support area and the second support areaare stiffer than the rest of the knitted spacer fabric to constrain loadtransfer when the seated occupant exerts the occupant load on thevehicle seat, and the first support area and second support area arepositioned to receive a pair of sit bones of the seated occupant. Thefirst knitted fabric layer may include a first layer area and a secondlayer area spaced apart from each other along the horizontal direction,the first layer area and the second layer area are stiffer than the restof the first knitted fabric layer to constrain load transfer when theseated occupant exerts the occupant load on the vehicle seat. The firstlayer area and second layer area are positioned to receive the pair ofsit bones of the seated occupant. The first layer area of the firstknitted fabric layer is aligned with the first support area of theknitted spacer fabric along a first vertical axis such that the firstvertical axis intersects the first layer area and the first supportarea. The second layer area of the second knitted fabric layer isaligned with the second support area of the knitted spacer fabric alonga second vertical axis such that the second vertical axis intersects thesecond layer area and the second support area, the first vertical axisis parallel to the second vertical axis, and the first vertical axis isspaced apart from the second vertical axis along the horizontaldirection. The first layer area of the first knitted fabric layer isaligned with the first support area of the knitted spacer fabric along avertical direction, the vertical direction is perpendicular to thehorizontal direction, the first layer area and the second layer area arealigned with each other along a longitudinal direction in order toreceive the pair of sit bones of the seated occupant, and thelongitudinal direction is perpendicular to the vertical direction andthe horizontal direction. Each of the first support area and the secondsupport area extends from the first knitted fabric layer to the secondknitted fabric layer to constrain load transfer from the first knittedfabric layer and the second knitted fabric layer through the firstsupport area and the second support area when the seated occupant exertsthe occupant load on the vehicle seat in order to support the pair ofsit bones of the seated occupant.

The present disclosure also describes a method for mechanicallyinterlocking a first knitted fabric layer and a second knitted fabriclayer. In some embodiments, the method includes: (a) placing the firstknitted fabric layer relative to the second knitted fabric layer so asto define a clearance between the first knitted fabric layer and thesecond knitted fabric layer to facilitate sliding movement between thefirst knitted fabric layer and the second knitted fabric layer; (b)sliding the first knitted fabric layer relative to the second knittedfabric layer along a horizontal direction until the first knitted fabriclayer and the second knitted fabric layer collectively reach apredetermined stacked position; and (c) placing the first knitted fabriclayer and the second knitted fabric layer on the outside surfaces of abladder while there is still space between the first knitted fabriclayer and the second knitted fabric layer. The molded skin is placedsolely on the outside surfaces while there is still space between thelayers. Then, when in service, a vacuum can be drawn to collapse abladder (e.g., an inflatable paradigm) and force the knit layers in tocontact and rigidizing them. Also, the nominal state is the collapsed,the bladder could be inflated so that the layers cease to make contactand allow for relative motion between the knit layers. The method mayfurther include drawing a vacuum to collapse the bladder in order to jamthe first knitted fabric layer and the second knitted fabric layertogether, thereby interlocking the first knitted fabric layer toward thesecond knitted fabric layer in the predetermined stacked position. Themethod may further include bending the first knitted fabric layer andthe second knitted fabric layer until the first knitted fabric layer andthe second knitted fabric layer collectively reach a predetermineddeformed shape. The method may further include inflating the bladder toseparate the first knitted fabric layer and the second knitted fabriclayer from each other in order to allow relative movement between thefirst knitted fabric layer and the second knitted fabric layer.

In some embodiments, the method includes: (a) providing the firstknitted fabric layer, the second knitted fabric layer, and a knittedspacer fabric interconnecting the first knitted fabric layer and thesecond knitted fabric layer; (b) simultaneously bending the firstknitted fabric layer, the second knitted fabric layer, and the knittedspacer fabric until the first knitted fabric layer, the second knittedfabric layer, and the knitted spacer fabric collectively reach apredetermined deformed shape; and (c) placing the first knitted fabriclayer, the second knitted fabric layer, and the knitted spacer fabric ona bladder after the first knitted fabric layer, the second knittedfabric layer, and the knitted spacer fabric are in the predetermineddeformed shape. The method may further include drawing a vacuum tocollapse the bladder to jam the first knitted fabric layer, the secondknitted fabric layer, and the knitted spacer fabric together, therebyinterlocking the first knitted fabric layer, the second knitted fabriclayer, and the knitted spacer fabric in the predetermined deformedshape. The knitted spacer fabric includes a plurality of pile yarnsinterconnecting the first knitted fabric layer and the second knittedfabric layer. The method may further include inflating the bladder toseparate the first knitted fabric layer and the second knitted fabriclayer from each other in order to allow relative movement between thefirst knitted fabric layer and the second knitted fabric layer.

The above features and advantages and other features and advantages ofthe present disclosure are readily apparent from the following detaileddescription of the best modes for carrying out the disclosure when takenin connection with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic, side view of a vehicle seat, including a lowerseat base and a seat back.

FIG. 2 is a schematic, cross-sectional view of the vehicle seat of FIG.1;

FIG. 3 is a schematic, cross-sectional view of the vehicle seat of FIG.2, depicting a seated occupant exerting an occupant load on the seat.

FIG. 4 is a graph illustrating a relationship between the occupant loadand the displacement of the seat shown in FIG. 2.

FIG. 5 is a schematic top view of the vehicle seat in accordance withanother embodiment of the present disclosure.

FIG. 6 is a schematic, cross-sectional view of the vehicle seat of FIG.5, taken along section line 6-6 of FIG. 5.

FIG. 7 is a schematic, side view of a first knitted fabric layer and asecond knitted fabric layer before being placed on a bladder.

FIG. 8 is a schematic, side view of a first knitted fabric layer and asecond knitted fabric layer of FIG. 7 placed on the bladder.

FIG. 9 is a schematic, side view of a first knitted fabric layer and asecond knitted fabric layer before being bent before being placed on thebladder.

FIG. 10 is a schematic, side view of a first knitted fabric layer and asecond knitted fabric layer of FIG. 9 placed on the bladder.

DETAILED DESCRIPTION

Referring to FIG. 1, a vehicle seat 10 (i.e., a seat for installation ina vehicle) is schematically illustrated. The seat 10 includes a lowerseat base 14, a seat back 18, and a headrest 22. In some embodiments,the lower seat base 14 may include a flexible base cover 26 that definesat least part of the outside of the lower seat base 14. For instance,the flexible base cover 26 may define a generally horizontal surface 30for supporting a seated occupant SO (FIG. 3). The seat back 18 ismounted with respect to the lower seat base 14. In some embodiments, theseat back 18 is rigidly mounted with respect to the lower seat base 14.In certain embodiments, the seat back 18 is pivotally mounted withrespect to the lower seat base 14 to allow the seated occupant SO toadjust the angle between the seat back 18 and the lower seat base 14.

In some embodiments, the seat back 18 may include a flexible back cover34 that defines at least part of the surface of the seat back 18,including a generally vertical surface 38, which provides support of theback of the seated occupant. The headrest 22 is mounted with respect tothe seat back 18 adjacent an upper edge of the seat back 18.

With reference to FIGS. 2-4, the vehicle seat 10 includes a firstknitted fabric layer 40 defining an outer surface 42. In the presentdisclosure, the term “knitted” does not include woven materials. Forinstance, the term “knitted” may refer to weft knitted materials. Inaddition, the vehicle seat 10 includes a second knitted fabric layer 44defining an inner surface 46, which is opposite the outer surface 42.The vehicle seat 10 includes an interconnection 48 directlyinterconnecting the first knitted fabric layer 40 and the second knittedfabric layer 44. The interconnection 48 may be a knitted spacer fabric,strips running lengthwise between the first knitted fabric layer 40 andthe second knitted fabric layer 44, vertical tubular links between thefirst knitted fabric layer 40 and the second knitted fabric layer 44.The interconnection 48 resiliently biases the first knitted fabric layer40 and the second knitted fabric layer 44 away from one another when nooccupant load OL is exerted on the vehicle seat 10. Further, theinterconnection 48 is configured to buckle when the seated occupant SOexerts an occupant load OL on the vehicle seat 10. In the depictedembodiment, the interconnection 48 includes a plurality of pile yarns 50directly interconnecting the first knitted fabric layer 40 and thesecond knitted fabric layer 44. Accordingly, the pile yarns 50 areconfigured to buckle when the seated occupant SO exerts the occupantload OL on the vehicle seat 10. The pile yarns 50 resiliently bias thefirst knitted fabric layer 40 and the second knitted fabric layer 44away from each other when the occupant load OL is exerted on the vehicleseat 10. The pile yarns 50 may be made of polyester, acrylic, nylon, orother suitable material. Further, the interconnection 48 is athree-dimensional knit structure.

The first knitted fabric layer 40 is more elastic than the secondknitted fabric layer 44 to conform to the seated occupant SO when theseated occupant SO exerts the occupant load OL on the vehicle seat 10.Also, the first knitted fabric layer 40 is more compliant than thesecond knitted fabric layer 44 to allow the first knitted fabric layer40 to conform to the seated occupant SO when the seated occupant SOexerts the occupant load OL on the vehicle seat 10. The second knittedfabric layer 44 is stiffer than the first knitted fabric layer 40 toprovide primary support for the seated occupant SO. To do so, thetension in the second knitted fabric layer 44 is higher than the tensionin the first knitted fabric layer 40.

With specific reference to FIGS. 3 and 4, when the seated occupant SOexerts the occupant load OL on the vehicle seat 10, the first knittedfabric layer 40 moves toward the second knitted fabric layer 44 and theinterconnection 48 collapses and bunches together, thereby transferringloads from the first knitted fabric layer 40 to the second knittedfabric layer 44. FIG. 4 shows a relationship between the occupant loadOL and the displacement of the vehicle seat 10. When the seated occupantSO sits on the vehicle seat 10, the vehicle seat 10 has a comfort areaCA in which the vehicle seat 10 conforms to the seated occupant SO, andthe interconnection 48 buckles and bunches in response to the occupantload OL, thereby enhancing comfort for the seated occupant SO.

With reference to FIGS. 5 and 6, in some embodiments, theinterconnection 48 includes a first support area 52 and a second supportarea 54 spaced apart from each other along a horizontal direction H. Theembodiments shown in FIGS. 5 and 6 are substantially similar to theother embodiments described above. Therefore, in the interest ofbrevity, solely the differences between this embodiment and theembodiment described above are described below. The first support area52 and the second support area 54 are stiffer than the rest of theinterconnection 48 (i.e., the compliant spacer area 56) to constrainload transfer when the seated occupant SO (FIG. 3) exerts the occupantload OL (FIG. 3) on the vehicle seat 10. The first support area 52 andsecond support area 54 are positioned to receive a pair of sit bones ofthe seated occupant SO (FIG. 3), thereby enhancing the comfort for theseated occupant SO. The compliant spacer area 56 is made of a softerfill material than the material forming the first support area 52 andthe second support area 54 to allow for better conformal properties andless load transfer than other vehicle seats. To do so, the fill material(e.g., pile yarns 50) forming the first support area 52 and the secondsupport area 54 is stiffer and/or denser than the fill material formingthe compliant spacer area 56 in order to contain the targeted loadingareas (i.e., the first support area 52 and the second support area 54)and to directly transfer loads from the first knitted fabric layer 40 tothe second knitted fabric layer 44, which is made of a material that isstiffer than the material forming the first knitted fabric layer 40. Asa result of this configuration, the comfort for the seated occupant SOseated on the vehicle seat 10 is enhanced. The first knitted fabriclayer 40 and the second knitted fabric layer 42 is each individuallytensioned (the tension in the first knitted fabric layer 40 relativelylower for more comfort compliance and the tension in the second knittedfabric layer 42 is relatively higher for suspension). The pile yarns 50are also tensioned or preloaded. Then, when the 3D knit (e.g., vehicleseat 10) is loaded, each of the filaments of the pile yarns 50 acts ascolumns in buckling, exhibiting a certain stiffness level or firmnessbefore buckling and becoming much more compliant and conformal. Then,finally when loaded enough, the first knitted fabric layer 40 may comeinto contact with the second knitted fabric layer 44, which due to itshigher tension/more dense construction serves to take the loads and as asuspension.

With continued reference to FIGS. 5 and 6, the first knitted fabriclayer 40 includes a first layer area 58 and a second layer area 60spaced apart from each other along the horizontal direction H. The firstlayer area 58 and the second layer area 60 are stiffer than the rest ofthe first knitted fabric layer 40 (i.e., the compliant layer area 62) toconstrain load transfer when the seated occupant SO exerts the occupantload OL on the vehicle seat 10. The compliant layer area 62 on the firstknitted fabric layer 40 can easily conform to the seated occupant SO toenhance comfort. On the other hand, the first layer area 58 and thesecond layer area 60 do not conform as much as the compliant layer area62 and allow load transfer from the first knitted fabric layer 40 to thesecond knitted fabric layer 44 through the first support area 52 and thesecond support area 54 in order to support the sit bones of the seatedoccupant SO. Accordingly, the first support area 52 and second supportarea 54 are positioned to receive the pair of sit bones of the seatedoccupant SO. As discussed above, the second knitted fabric layer 44 isstiffer than the first knitted fabric layer 40 to support the seatedoccupant SO. To do so, the second knitted fabric layer 44 can beconfigured with more constraining stitch pattern, stiffer yarns, and/ormore highly pretensioned yarns than the first knitted fabric layer 40.The first layer area 58 of the first knitted fabric layer 40 is alignedwith the first support area 52 of the interconnection 48 along a firstvertical axis Y1. As such, the first vertical axis Y1 intersects thefirst layer area 58 and the first support area 52 to support one of thesit bones of the seated occupant SO. The second layer area 60 of thesecond knitted fabric layer 44 is aligned with the second support area54 of the interconnection 48 along a second vertical axis Y2. As such,the second vertical axis Y2 intersects the second layer area 60 and thesecond support area 54 to support at least one of the sit bones of theseated occupant SO. The first vertical axis Y1 is parallel to the secondvertical axis Y2 to ensure that the first layer area 58 and the secondsupport area 60 support the sit bones of the seated occupant SO. Thefirst vertical axis Y1 is spaced apart from the second vertical axis Y2along the horizontal direction H. The interconnection 48 functions as apad to sustain shear loads.

The first layer area 58 of the first knitted fabric layer 40 is alignedwith the first support area 52 of the interconnection 48 along avertical direction V. The vertical direction V is perpendicular to thehorizontal direction H. The first layer area 58 and the second layerarea 60 are aligned with each other along a longitudinal direction L inorder to receive the pair of sit bones of the seated occupant SO. Thelongitudinal direction L is perpendicular to the vertical direction Vand the horizontal direction H. Each of the first support area 52 andthe second support area 54 extends from the first knitted fabric layer40 to the second knitted fabric layer 44 to constrain load transfer fromthe first knitted fabric layer 40 and the second knitted fabric layer 44through the first support area 52 and the second support area 54,respectively, when the seated occupant SO exerts the occupant load OL onthe vehicle seat 10 in order to support the sit bones of the seatedoccupant SO.

With reference to FIGS. 7 and 8, all of the vehicle seats 10 describedin the present disclosure can be created with a method for interlockingthe first knitted fabric layer 40 and the second knitted fabric layer44. In this method, the first knitted fabric layer 40 is placed relativeto the second knitted fabric layer 44 such that a clearance CL isdefined between the first knitted fabric layer 40 and the second knittedfabric layer 44. Due to this clearance CL, the first knitted fabriclayer 40 and the second knitted fabric layer 44 can slide relative toeach other in the horizontal direction H (see arrows LT and RT). Theclearance CL also allows the first knitted fabric layer 40 and thesecond knitted fabric layer 44 to be bent, for example, in the directionindicated by double arrows BT. For instance, the first knitted fabriclayer 40 and the second knitted fabric layer 44 can be bent until thefirst knitted fabric layer 40 and the second knitted fabric layer 44collectively reach a predetermined deformed shape. Thereafter, the firstknitted fabric layer 40 and/or the second knitted fabric layer 44 areslid relative to the other along the horizontal direction H until thefirst knitted fabric layer 40 and the second knitted fabric layer 44collectively reach a predetermined stacked position. After (and while)the first knitted fabric layer 40 and the second knitted fabric layer 44are in the predetermined stacked position but spaced apart from eachother, the first knitted fabric layer 40 and the second knitted fabriclayer 44 are placed on the outside surfaces of a bladder 64 as shown inFIG. 8. While there is still space between the first knitted fabriclayer 40 and the second knitted fabric layer 44, the molded skin (e.g.,the first knitted fabric layer 40 and the second knitted fabric layer44) is placed only on the outside surfaces of the bladder 64 (e.g., aninflatable paradigm). Then, when in service, a vacuum can be drawn tocollapse the bladder 64 and force the first knitted fabric layer 40 andthe second knitted fabric layer 44 to be in contact, thereby rigidizingthe first knitted fabric layer 40 and the second knitted fabric layer44. Once the first knitted fabric layer 40 and the second knitted fabriclayer 44 are disposed on the bladder 64 in the predetermined stackedposition, a vacuum is drawn in the bladder 64 to jam the first knittedfabric layer 40 and the second knitted fabric layer 44 together, therebyinterlocking the first knitted fabric layer 40 toward the second knittedfabric layer 44 in the predetermined stacked arrangement to create atextile structure with enchanted stiffness and rigidity. A vacuum device66 can be used to draw air A (or other suitable gas) from the bladder 64to force the first knitted fabric layer 40 toward the second knittedfabric layer 44 in order to interlock the first knitted fabric layer 40and the second knitted fabric layer 44 together. Also, the nominal stateis the collapsed state, the bladder 64 could be inflated so that thefirst knitted fabric layer 40 and the second knitted fabric layer 44cease to make contact and allow for relative motion between the firstknitted fabric layer 40 and the second knitted fabric layer 44.

With reference to FIGS. 9 and 10, the method for mechanicallyinterlocking the first knitted fabric layer 40 and a second knittedfabric layer 44 includes providing the first knitted fabric layer 40,the second knitted fabric layer 44, and the interconnection 48interconnecting the first knitted fabric layer 40 and the second knittedfabric layer 44. Then, the first knitted fabric layer 40, the secondknitted fabric layer 44, and the interconnection 48 are simultaneouslybent with, for example, bending tools 65, until the first knitted fabriclayer 40, the second knitted fabric layer 44, and the interconnection 48collectively reach a predetermined deformed shape. Next, the firstknitted fabric layer 40, the second knitted fabric layer 44, and theinterconnection 48 are placed on the outside surfaces of the bladder 64after the first knitted fabric layer 40, the second knitted fabric layer44, and the interconnection 48 are in the predetermined deformed shape.After (and while) the first knitted fabric layer 40 and the secondknitted fabric layer 44 are in the predetermined deformed shape, thefirst knitted fabric layer 40 and the second knitted fabric layer 44 areplaced on the outer surfaces of the bladder 64 as shown in FIG. 10. Oncethe first knitted fabric layer 40 and the second knitted fabric layer 44are on the bladder 64, a vacuum is drawn to collapse the bladder 64 inorder to jam the first knitted fabric layer 40 and the second knittedfabric layer 44 together, thereby interlocking the first knitted fabriclayer 40 toward the second knitted fabric layer 44 in the predetermineddeformed shape to create a textile structure with enchanted stiffnessand rigidity. The vacuum device 66 can be used to draw air A (or othersuitable gas) from the bladder 64 to force the first knitted fabriclayer 40 toward the second knitted fabric layer 44 in order to interlockthe first knitted fabric layer 40, the interconnection 48, and thesecond knitted fabric layer 44 together in the predetermined deformedshape.

While the best modes for carrying out the disclosure have been describedin detail, those familiar with the art to which this disclosure relateswill recognize various alternative designs and embodiments forpracticing the disclosure within the scope of the appended claims.

What is claimed is:
 1. A vehicle seat, comprising: a first knittedfabric layer defining an outer surface; a second knitted fabric layerdefining an inner surface, wherein the inner surface is opposite theouter surface; an interconnection coupling the first knitted fabriclayer to the second knitted fabric layer, wherein the interconnectionresiliently biases the first knitted fabric layer and the second knittedfabric layer away from one another, and the interconnection isconfigured to buckle when a seated occupant exerts an occupant load onthe vehicle seat; and wherein the first knitted fabric layer is moreelastic than the second knitted fabric layer to conform to the seatedoccupant when the seated occupant exerts the occupant load on thevehicle seat.
 2. The vehicle seat of claim 1, wherein theinterconnection includes a knitted spacer fabric, and the knitted spacerfabric includes a plurality of pile yarns interconnecting the firstknitted fabric layer and the second knitted fabric layer.
 3. The vehicleseat of claim 2, wherein the plurality of pile yarns are tensioned. 4.The vehicle seat of claim 1, a tension in the second knitted fabriclayer is higher than a tension in the first knitted fabric layer.
 5. Thevehicle seat of claim 1, wherein the interconnection includes a firstsupport area and a second support area spaced apart from each otheralong a horizontal direction, the first support area and the secondsupport area are stiffer than a rest of the interconnection to constrainload transfer when the seated occupant exerts the occupant load on thevehicle seat, and the first support area and second support area arepositioned to receive a pair of sit bones of the seated occupant.
 6. Thevehicle seat of claim 5, wherein the first knitted fabric layer includesa first layer area and a second layer area spaced apart from each otheralong the horizontal direction, the first layer area and the secondlayer area are stiffer than a rest of the first knitted fabric layer toconstrain load transfer when the seated occupant exerts the occupantload on the vehicle seat, and the first layer area and second layer areaare positioned to receive the pair of sit bones of the seated occupant.7. The vehicle seat of claim 6, wherein the first layer area of thefirst knitted fabric layer is aligned with the first support area of theinterconnection along a first vertical axis such that the first verticalaxis intersects the first layer area and the first support area.
 8. Thevehicle seat of claim 7, wherein the second layer area of the secondknitted fabric layer is aligned with the second support area of theinterconnection along a second vertical axis such that the secondvertical axis intersects the second layer area and the second supportarea, the first vertical axis is parallel to the second vertical axis,and the first vertical axis is spaced apart from the second verticalaxis along the horizontal direction.
 9. The vehicle seat of claim 8,wherein the first layer area of the first knitted fabric layer isaligned with the first support area of the interconnection along avertical direction, the vertical direction is perpendicular to thehorizontal direction, the first layer area and the second layer area arealigned with each other along a longitudinal direction in order toreceive the pair of sit bones of the seated occupant, the longitudinaldirection is perpendicular to the vertical direction and the horizontaldirection.
 10. The vehicle seat of claim 9, wherein each of the firstsupport area and the second support area extends from the first knittedfabric layer to the second knitted fabric layer to constrain loadtransfer from the first knitted fabric layer and the second knittedfabric layer through the first support area and the second support areawhen the seated occupant exerts the occupant load on the vehicle seat inorder to support the pair of sit bones of the seated occupant.
 11. Amethod for mechanically interlocking a first knitted fabric layer and asecond knitted fabric layer, comprising: placing the first knittedfabric layer relative to the second knitted fabric layer so as to definea clearance between the first knitted fabric layer and the secondknitted fabric layer to facilitate sliding movement between the firstknitted fabric layer and the second knitted fabric layer; sliding thefirst knitted fabric layer relative to the second knitted fabric layeralong a horizontal direction until the first knitted fabric layer andthe second knitted fabric layer collectively reach a predeterminedstacked position; and placing the first knitted fabric layer and thesecond knitted fabric layer on a bladder while there is still spacebetween the first knitted fabric layer and the second knitted fabriclayer.
 12. The method of claim 11, further comprising drawing a vacuumto collapse the bladder to jam the first knitted fabric layer and thesecond knitted fabric layer together, thereby interlocking the firstknitted fabric layer toward the second knitted fabric layer in thepredetermined stacked position.
 13. The method of claim 11, furthercomprising bending the first knitted fabric layer and the second knittedfabric layer until the first knitted fabric layer and the second knittedfabric layer collectively reach a predetermined deformed shape beforeplacing the first knitted fabric layer and the second knitted fabriclayer on the bladder.
 14. The method of claim 11, further comprisinginflating the bladder to separate the first knitted fabric layer and thesecond knitted fabric layer from each other in order to allow relativemovement between the first knitted fabric layer and the second knittedfabric layer.
 15. A method for mechanically interlocking a first knittedfabric layer and a second knitted fabric layer, comprising: providingthe first knitted fabric layer, the second knitted fabric layer, and aknitted spacer fabric interconnecting the first knitted fabric layer andthe second knitted fabric layer; simultaneously bending the firstknitted fabric layer, the second knitted fabric layer, and the knittedspacer fabric until the first knitted fabric layer, the second knittedfabric layer, and the knitted spacer fabric collectively reach apredetermined deformed shape; and placing the first knitted fabriclayer, the second knitted fabric layer, and the knitted spacer fabric ona bladder after the first knitted fabric layer, the second knittedfabric layer, and the knitted spacer fabric are in the predetermineddeformed shape.
 16. The method of claim 15, further comprising drawing avacuum to collapse the bladder in order to jam the first knitted fabriclayer, the second knitted fabric layer, and the knitted spacer fabrictogether, thereby interlocking the first knitted fabric layer, thesecond knitted fabric layer, and the knitted spacer fabric in thepredetermined deformed shape.
 17. The method of claim 16, wherein theknitted spacer fabric includes a plurality of pile yarns interconnectingthe first knitted fabric layer and the second knitted fabric layer. 18.The method of claim 15, further comprising inflating the bladder toseparate the first knitted fabric layer and the second knitted fabriclayer from each other in order to allow relative movement between thefirst knitted fabric layer and the second knitted fabric layer.